Process for gas making



June 5, 1928. I I

' H. R. BERRY PROCESS FOR GAS MAKING l t u 4 8 W Y 2 B 9 W Glad;

A TTORNEY.

June 5-, 1928 H. R.'BERRY rnbcnss FOR GAS MAKING Filed April 5, 1928' 4 hetS-Shea 2 ..INVENT10R.

1 TTORNEY.

June 5, 1928 H. R. BERRY PROCESS FOR GAS MAKINL Filed April 5, 1928 4 Sheets-Sheet 3 INVENTOR. W4 W. 3

ATTORNEY.

, 1928 -4 Shee" r.s-Sheet' 4- June 5,' 1928.

. H. R. BERRY PROCESS FOR GAS MAKING Filed April. 5

7 w s U M R E 5 5 mo m N. 4 I. E M V 7 y v m 4 r l. 1/ H \l I x v TH wJ i I .1 M W J |H v W0 v 50 ..I% if I Rf P l|ll| EU M A7 EL m WM R .M. n"

TAP TAP A TTORN Patented June 5, 1928.

UNITED STATES PATENT-"OFFICE.

HAROLD R. BERRY, OF BROOKLYN, NEW YORK.

PROCESS FOR GAS MAKING.

Application filed April 5,

1o tication in application of the process to coal.

The process embraces the use of compound carbon in volatile fractions of carbonaceous materials to produce hydrocarbons in the gas, and use of fixed carbon of carbonaceous materials to produce carbon oxides and hydrogen in the gas.

The process includes, for instance, production of an artificial combustible gas, similar in composition to carburetted water-gas manufactured from hard .coal and oil, by the use of bituminous coal, steam and hcatwithout oil; in which operation the oil-gas components of present practice enriched watergas are obtained from the bituminous volatile and not from oil and blue water gas components from potential coke fractions of soft coal, instead of from hard coal or coke.

The process contains provisions for coal volatiles, now combusted in the air blast period of water-gas manufacture, to be ,reclaimed by their conversion into enriching fractions of the gas. g

The process gas is useful for'heating and power generation and the flexibility of regugoverns the use of the process gas, minimizs lation which obtains with gaseous fuels,

1928. Serial No. 267,609.

.ing the problems of peaks andstand-by fires;

affording immediate steam response to fresh fuel and a nearer approach to complete combustion with reduced air quantities. 40 For the purpose of showing certain distinguishments of the process gas, mention follows of a number of artificial gases in common use.

1. Bic stfumace gaees.-These are byto 1 product, blast furnace gases. They contain carbon monoxide from reactions of the fut nace charge, together with combustion roducts of carbon dioxide and nitrogen of arge proportion jointly, well over one-half the gas volume. The present process provides that combustion products be exited from the operation and diverted from the gas and that carbon combustion be incident to gas making, not smelting.

2. Producer gas.'This gas is a primary product but, like blast furnace gases, combustion products are entrained in its composition. Indiscriminate combustion of volatile and carbon fractions of the fuel by 60 air blasting, characterizes its manufacture. In production of this gas, steam is sometimes added, which somewhat changes the gasmaking reactions; but'in producer gas the conglomerate of all reaction resultants constitutes the highly nitrogenous, thermally deficient product of only some 50% greater heat value than by-product blast furnace gases. Among other difierentiations, the present process is distinguished from producer gas practice inthe disposal ofcombastion products outside the gas-make and distillation of coal volatiles, Without combustion air contact for-their reclamation in the product gas. I v

3. Oil gas is obtained by the heat treatment of oil. It is a hot gas usually containing large percentages of methane and unsaturated hydrocarbons. It is used straight.

and. also for carburetion. The process gas of this specification is obtained from coal without oil and incorporates, as part of the process, carbon reaction With steam.

4. Coal gas, asv a name, is diversifiedly applied. The distilled volatile of coal, par.

ticularly' of soft coal, is coal gas, yet when coke production is the chief purpose, it is called coke-oven gas. The town gas of tion clarifying if by coal-gas be intended,

not producer gas as before described, but coal volatiles, distilled by heat, applied outside the coal container; combustion products notentering the distillate.

The making of gas, by the process presented, differs from coal gas, so designated. Among these differences, the process reduces heat losses due, among other things, to radiation and transmission by combusting part of the coal under treatment to satisfy distillation heat requirements, yet diverts the combustion prod-. ucts from the gas-make; and also uses the heat so developed for temperature elevation, incident to the carbon-steam reactions which are prescribed to occur by the process.

5. Water-gas.This gas, by many regarded as the most efficient, economic and practical of all artificial gases, is the product of the carbon and steam reaction at high temperature. The ratio of the carbon oxides to each other is chiefly dependent on temperatures and these oxides with the hydrogen released in their formation, constitutes the gas which is produced by intermittent air blast and steam contact. Part of the coal charge is combusted in the blast to afford gas-making heats for the run. No reclamation of coal volatiles is practiced in water-gas manufacture, the largest operations using anthracite and coke. The Watergas, or blue gas, emanating from the generator is mixed with oil gas for enrichment and this final mixed gas product is the gas, Which is a counterpart in composition to thatproduced by the present process without the use of low volatile fuel and oil.

Distinguishment of the present process from water-gas practice is shown in application of the process to the production of a gas similar in composition to carburetted watergas. As the volatile fraction of anthracite coal or coke is too small to contain an amount of carbon which equals that compounded in the illuminant fraction of customarily rich carburetted Water-gas, to produce such gas, by'the process presented, requires the use of carbonaceous material, of higher volatile percentage than anthracite coal or coke, for instance, bituminous coal. In explanation, suppose there is found to be by analysis two pounds of carbon more in a certain amount of coal than that found as fixed carbon. This two pounds 0 carbon, then, with heat, is distillable from the coal, it constituting a component of the volatiles.

Appearance of this carbon as pure carbon in vapor phase, under the distillate heats employed, is impossible. Such carbon occurence is possible only if the carbon be in union with another element or elements, if it be in compound. Thus all carbon available for volatiles, is either actually or potentially, compound carbon, and no carbon is available from coal for hydrocarbon gases and gas illuminants except it be contained within the volatile fraction. The only modification of this Would-be through union of hydrogen and'carbon, which is quite impossible, to detectable extent, in the presence of the carbon monoxide quantities present.

Thus the process provides for derivation of illuminants from volatiles and procurement of carbon oxides and hydrogen'from fixed carbonor that precipitated treatment of the volatiles.

Application of the process in the production of a gas, similar to carburetted waterand steam, ishad in the use of bituminous coal and steam without oil and consists in combustin'g part of a coal charge, which has rut;

. gas, manufactured from anthracite coal, oil

been previously subjected to devolitization,

and using heat, produced by the combustion, to first, distill volatiles from the remainder of the coal 'charge and, second, to supply thermal requirements for .reacting part of the hot carbon and steam into gas, and uniting' these reaction products with the distillates to form the gas.

If the process gas be made from coal of a small volatile percentage and if water gas of present practice be enriched with but small 'oil-gas amounts, the thermal value of the product-gas is increased but little over that of the blue water gas; but, if high volatile coal, for instance bituminous coal as cited, be used in making the process gas, and large oil quantities are employed to enrich the gas of present practice, the thermal values of the gas products are high.

p 12:, In this application of the process is em-v analysis of hard coal and oil; that the ultimate constituentsof present practice carburetted water-gas, derived from low volatile fuel and oil are balanced, in kind and quantity, in the elemental make up of soft coal and steam, without oil. That, as gas illuminants are hydrocarbons,- composed of hydrogen and carbon, and as the direct union of hydrogen and carbon does not oc cur under the operative conditions provided, the carbon in the coal to equasion that in the illuminants of the gas, must be Within the coal volatiles, the fixed carbon of the coal reacting to bluewater gas components, but not to enrichment quantities.

The state of occurrence of the coal volatile, however, is not agreed upon. Among the elements constituting the volatile there always" are oxygen, hydrogen and carbon. In what compounds these elements abide in coal, is conjecture. Emanations of volatile fractions from the same coal difler, dependent upon temperatures, time, exit rapidity and even the design of the retort, said W. H. Coleman. Merely the heat needed for their extraction, seems to produce reaction and modification of distillates. Condensates may contain phenol, creosote audits mixtures, aniline, when compound nitrogen is present, the carboxyl group with its assortment of fatty acids, and the whole gamut of by-product coke oven recoveries, butwhat native union in the raw unheated coal, subsi-sts between the elements of the coal volatile is simply guessed at.

The oxygen may be in certain of the above compounds or in alcohols, which break up into -aliphatics, through oxidations pro-ducing the above. The last happening is often claimed, because, as the oxygen content of volatiles increases from around 5% to 11 or l2% (Duefi'e), olefines and heavy unsaturates also increase. This explained on the Present practice'enriched blue water gases vary, dependent largely upon the character and quantity of the oil used for enrichment. The process gas products likewise vary,-".de-. pendent largely upon the character and amount of volatiles in the coals used. Of 79 necessity, the constituents of all and varied enriched blue water gases are not equaled in every type and variety of coal. In general .a low volatile'coal is the counterpart of a lean water-gas and with increase of coal volatile is a correspondent increase in gas richness.

Generalization in the comparisons bee, tween hard and soft coals, oils and gases, made here, in. support of the process, may be supplemented and illust-rativelyempha- 30 sized by citation of a specific coal' and a specific gas-which equasion each other. The references are of ready access and authentic.

The coal; elements and their weights. Citation, Engineers Handbook, LionelS. Marks, Harvard University, Massachusetts Inst. Tech. first edition. tenth impression, McGraw-Hill Book Co., New York, London, page 600.

Table 2 (continued). i Locality, bed, etc, or commercial name of coal, Marianna, .Pittsburg bed. I p

Proximate analysis Ultimate analysis T as received as received" n 2 W9 *5. g is .Q n g 2 :2 g a :1, a q 8 '3 a: 5 M 5 o o 0 a H s '8 '3 t! e w E 3 '5 .5 g '5 E Q Q i a is 1 cm b1 0 o 1 7 The above quotation is verbatim. For reference convenience, a completdanalysis will be shown from the above. The total carbon shown, for instance, "in the ultimate is 78.76 pounds, but in the proximate only 57.77

theory, that oxygen, from an alcohol, x

45 through other union, yields the hydrocar- 'PQ PP as Of necessity, W

bons Within the named range of Oxygen difference 1s the amount of carbon that s increase, methane increases and hydrogen n fixed, b 111 compound assoclatloll 1I1 decreases, Y i I the coal VOlfltllGS. The complete analysis Though identity of the compounds, consti- Q 50 tuting the volatile fraction 0f 003.], iS COBjGC .Gomrrrxrn ANALYSIS (100 POUNDS) -tural,and the chemical unions of the dist'il- I I v 115 lates vary and depart from the state of 1121- Moisture 1.44 I tive occurrence, nevertheless, the kind and g ifffff f quantity of the respective elements consti I 5 tuting the volatile matter, as occurrent in Carbon 1 the coal or abstracted therefrom, are known" Oxygen" 34-61 Total 100.00

and each element, in accordance with its nweighnhas a given heat value. Subject to the plus or minus of formation heats, 60 these elements, though compounded, yield,

I in combustion, this heat.

Delivery of this heat, through combustion of a gas, into which these elements enter, is

their conversion into gas illuminants.

The complete analysis is a combination of the proximate and ultimate, which shows,

without computation, the composition of the fixed carbon and ash would go to constitute the coke. In the volatileso driven off, is provided the raw materialfor the by-product coke oven and the constituents for illum inants of enriched water gas. In the potential coke is the fixed carbon reactable with steam into water gas.

Sulphur, shown in analysis, is neither fixed carbon, volatile, moisture or'ash of the proximate, but, isclassified inthe complete analysis amongthe volatiles,-and probably with correctness, as it vaporizes around 900 F .and' is frequent in the SO and H S compounds.

In assembling the data, a standard carburetted water gas analysis follows. The gas was produced by best practice, using hard coal and oil. In citing the gas, the purpose Willbe, to show that every element and compound init, illuminants and straight water gas, obtained from boththe oil and hard coal used, are exactly equationed in the soft coal analysis, before cited.

vGrAs ANALYSIS Kents Handbook 1923-T.enth Edition, John Wiley & Sons, N. Y., page 899.

Composition by volume, water-gas,

' Worcester. Nitrogen 2. 64 Carbonic acid 0.14 Oxygen 0.06 Ethylene 11. 29 Propylene 00.00 Benzole vapor 1. 53 Carbonic oxide 28.26 l\Iarsh-Gas 18.88 Hydrogen. 37.20

Density:

Theory 0.5825 Practice; 0.5915 B. T. U. from 1 cu. ft.:

Water liquid 650.1 ater vapor 597.0 Flame temperature, F. 5311.2

Average candle-power 22.06

The above citation is verbatim. Only slight comparison is possible, with the data thus far cited. The gas analysis shows a group of gases, and certain volumetric percentage, aggregating 100. The coal analysis shows an aggregation of dissimilar things totaling in Weight 100. v

The use of common denominations is necessary for comparison. The reduction of compounds to elements and of volumes to weights-is obviously necessary.

A tabulation of conversion values here employed follows, containing, also, .combus- 65 tion heat yields in B. T. Us.

Mol.

Volumes, 60 F., 30 Wt Nitrogen N Carbonic acid...... 002" Oxygen O Marsh gas Hydrogen "Hz" Carbon G Sulphur S.. 32 Ash Moisture "H2O" Wt. Air N. 76.85; 0. 23.15 13.059

Hempels Gas Analysis. Lord and Bass. 1, Jules Thompson, Thermo. Inves., Favre & Silberman.

( U. G. I. table of gas constants.

Lamzes Goal Tar and Ammonia.

No thermal value is given the ash, certain calcites may shift between carbonates and oxides and readjustments of alkaline and ferrous compounds occur, but the effect on heat will be disregarded.

Lucke, Thermodynamics at 32 F., 29.92 (Ledoux) shows 341 B. T. U. reducing to 30-60 is 323.5.

( Ganot Physics, U. G. I. tables.

( Thompson, Thermo. Inv. calc.

By use of the above equivalents, the weight of each gas shown in the analysis is derived, as 1s also, the identity and weight of the composing elements. One thousand cubic feet of the reference gas is thus shown constituted as follows:

Cufft. B. T. U. Wt. lb. C. 0. H2

The respective compositions of the gas and coal samples cited, are now expressed in comparable terms.

Methane, for instance, of the gas, is eX pressed, not only as originally given, 188.8 cu. ft. out of 1000 cu. ft.'of the total gas, but also now is shown as 7.991 pounds, of which 5.993 pounds are carbon and 1.998 pounds are hydrogen.

On the one hand is shown 100 pounds of soft coal, composed of the aggregate weight of its components, on the other hand, is 1000 cu. ft. of carburetted water gas, manufactured from hard coal and oil, now shown as the weight aggregate of its constituting gases, each of which gases is also shown as stituting element's.

basis, a trial constant, for a weight balance,

has been calculated as 1.3125, which will .be found to check in the coal analysis.

The purpose of the following weight balance is to show that all the elements, in their 15 required proportions, constituting the car buretted water gas cited, and manufactured from hard coal and oil are contained in the soft coal.

The weight balance follows:

Elli! Cuhnttol I! ml in: M Md Ill at].

1000 cu. 1:. 11112.! :uJL, Int "fume. On

rm mum a. '4.

19B Id. 2.599. MI llndnnnll tr-11h! In"! Q L Cu." 23.? .lb ll. 0.. I. I Amy-u ammnm can and snu cumin: mm 1.4 602 .0 .u 100 paw-ids um em ml 243.02 pmmdl nucan .5 e i 051 l6 a n nth 04- mu Ithylm 112m 0 140.10 2h, .1 10.9! 1.54. 9.41: 34mm cm. mam al mm. mm; umam 0 :4 20.00 mmi? 4.145 I .an mm 33. can Anny: frna am mo 45 CNDUMC and. 32.5 c 0 s10 92 iiamgii. 21.41 11.1. 15."

m ni fix vol. (10;!) wk! Kudhonk m za., .soo mu 0 c c 5 Uni-11H) we. a I. 247m ammo. 10.310 2.6:; 1.15s

31 in v (w mm" 1.44 1.44 mm;- 312. I2- 450.25 rum-1.2 2.54 2.54

m 6.18 5.1a Iltrog- 26.4 I an. 2 57 2 :1

14m Carl-Ian 67.77 logy. mu igagg asi' 1 my 4.510 22.22 5| n. rum 2 n1 imam heat! and In (I) 29.1w aL z n. mam u! an a" human" tnhm an can at In...

m a (a a4 is u 1 co 5:2.0 123.571. 1.30: 12.1: NA?

Banliblo a:

mm) b) 1.11 25.04 a u no; 10.5 1.32 .as .95 L teu! an: i

mum- (c) .90 a 1B $.10 b an, 00,900 1.32 1.32

ZVIPM'aHbn mama-4 (a) .m a in M so gg Lg; 1:. 11.13:

Skill! 4 h i v lnlmtl (a) 1.92 15 Ml mum-nag 100 ml not! tu Ill lie-- when" 35.61. mu an (mm) 951. 1 51 12!. um: 4.519 E. am mi 06 a.

25.44 a: V a s: I

In 0mm 7, L8 Ian}: 4-

:u on

CARA! 2099 an" Eydrvu'lfl 5.2a

Mphur .12 n.41 4.510 3.51

can can: (1.64.) 1mm no um am a on o no smu (121.) I as 62 mm. |.!.u.

imam-mu 128.62 mm 1 on m an: and Inn .24 41.84 (on cm. 640 I341 Hull 3053033193841 Q57 BB'II lateflll, in) 122 52 l3 B2 gases, shown in column 2,-1s segregated, in

proper ratio, to -the constituting elements,

and these apportioned weights are set down in either column 3 or 4, dependent upon Whether the particular gas be an illuminant and derived from oil, or a constituent of blue water gas, derived from coal and steam.

,DlVlSlOIlS 2, 3 and 4, show the composition of 1312.5 cufft. of the Kent reference gas, divisioned into respective weights of their composing elements of hydrogen, carbon and oxygen, classified appropriately as illumi- (saturated steam tables).

'nants and straight water gas andsummarized as follows Division 5 of the weight balance.-All the coal, either hard or soft, fed into a gas generator, does not enter the gas. Heat is required to drive off the volatile of soft coal,-

make steam, elevate temperatures and supply reaction heat requirements. These needs are satisfied by combustion of part of the coal charge. To determine the part of the coal used for heat production and the art reacted into gas, reference is again ha to the Kent citation, in which appears a heat balance of a carburetted water gas operation.

I 1000 cu. ft. of the-gas is shown to be a. mixture of 645 cu. ft. of blue water 'gas and 355 cu. ft. of oil. gas. 23.5 pounds of carbon, exclusive of ash and unconsumed coal, is used in making the 645 cubic feet of Water gas, or

36.34 (a) pounds of carbon are used in combustion and reaction to produce 1000 cu. ft.

of water gas,

carbon allowance. Figuring the volatile as requiring an average temperature elevation of 1000" F. for their liberation from the coal, their sp. ht. .45 and their quantity, the 34.61 pounds of volatile in the 100 pound coal sample cited, the heat requirement for sensible temperature elevation of the volatiles is (1000 X .45 X 34.61), or 15,574 B. T. U,

requiring the combustion of 1.11 (1)) lbs. of coal, at 14,000 B. T. U. per pound.

Not only, however, must the volatiles be heated but also thermal force be supplied to break the tension which holds them within the coal.

On the basis of the same heat requirement, weight for weight, for production of gas from petroleum as its liberation from soft coal, this'heat requirement is 34.61: 35 as X: 12,841 B. T. U.; wherein 3 is the heat rendered latent in the gasificat-ion of oil. (H. in the Kent reference), 2, the mass of 5 gallons of petroleum at 7 pounds to the gallon; 1, the weight of the coal volatile and X, the B. T. U.s required to liberate the volatiles from the soft coal. X is 12,700 B. T. U. or .90 pounds of carbon (0).

Though water gas I steam requirements have beenequationed under count a, no

allowance is made for ridding the .soft coal of its moisture percentage. This factor will be 1244 (weight of moisture in the'coal sample) X In the steam requirement for water gas manufacture, estimated in count (1 above, the provision embraces the heat requirements of steam after it enters the generator, but does not include the heat to make the steam before it enters the apparatus.

The heat absorption for water at 60 F. to steam at 350 F. is 1160 B. T. U. per pound 23.76 pounds of steam enter the composition of 1000 cu. ft.

of water gas see water gas analysis). Thus,

27,562B. T. (1160 23.76) are required in steam composition in the'production of 1000 heat from the generator to make all the steam used in making the gas. This, of course, entails no fuel cost for steam.

A number of factors figure in these constructions involving heat transmission and excess steam in the gas making, but the heat surplus is so large that no particular ingenuity is required to obtain! all needed steam making heats from the exhaust.

Ignoring exhaust heat economy, and figuring coal at 14,000 B. T. U. per pound and a boiler etficiency of 3 pounds of coal (e) will produce the steam required for 1000 cu. ft. of gas.

1160 x 23.6 mo

For reference convenience, the above items are tabulated as follows and referred to on the weight balance by the letters shown, viz;

Carbon pounds. ((1) Amount of carbon required for use. exclusive of ash and uuconsuuu-d coal. to produce 1000 cu. ft. water gas (b) For elevating the temperature of volatiles in 100 pounds of soft (0:11 (per cool sample)- 1. 11 (1:) For heat to liberate volatiles from the above- 00 (d) For moisture evaporation of 100 pounds sample coal 5 .111) 1;- QSJQ 1.02 (6) L01 stiam 1n1l1ng 1000) (f) For estimated loss in unconsumed coal and ash per 1000 feet of water gas make (see Kent reference) 9.90

The amount of fixed carbon in the Pittsburgh coal sample,="show.n in analysis. 1s 57.77 pounds. This amount of carbon seems sutlicient compared with the above .totah to drive off the volatiles, satisfy heat requirements, and produce some 1000 cu. ft. of wathe volatile and hydrogen. The steam quantity entering the gas, is shown horizontally from the fixed carbonfigures of the coal analysis, under caption 6.

Below the gas distribution shown in divisions 1, 2, 3 and 4 is incorporated an addi tional640 cu. ft. of gas composed of the familiar products of the water gas reaction. After satisfaction, through combustion, of

the thermal requirements placed upon the fixed carbon of the coal, the residue carbon, with the steam quantities shown, constitutes this additional 640 cu. ft. Hard coal with oil is shown in balance with soft coal without oil; the determinations being derived from authentic analyses.

Without noting the small nitrogen quantity, valueless in combustion, the gas of 1953 cu. ft. is in complete weight balance with the 100 pound coal sample plus 28.62 pounds of steam.

1. The total weight of the carbon in the volatile fraction of the coal is 20.99 pounds; the weight of carbon in the illuminant fraction of the gas is 20.99 pounds.

The remainder of the carbon in the coal is the fixed carbon, 57.77 pounds. Part of this carbon is shown either wasted 0r combusted, for purposes before described and referred to by letters on the weight balance, thus (b) 1.11 (c) .90 (a 115 e (e) 1.92

' Total 33.44 pounds of fixed carbon combusted or wasted in the gas making, leaving pounds of the fixed carbon of the coal available for reaction into water constituents. The total amount of carbon in the non-illun1inant part of the gas is 24.33 pounds.

3. The steam quantity, 28.62 pounds, is distributed in proper ratio, to hydrogen, 3.18 pounds, and oxygen 25.44 pounds. To this oxygen quantity, provided by the steam, as added the 7.61 pounds of oxygen in the coal, making 33.05 pounds of oxygen in the steam and coal supplied. The total oxygen content of the gas is 33.05 pounds.

4. When the oxygen of the steam thus joined the carbon of the coalfof necessity, the 3.18 pounds of hydrogen in" the steam was released; adding to this the 5.23 pounds of hydrogen in the coal, makes 8.41 pounds. In the gas, its illuminants contain 4.510 pounds and, infree state, are 3.00 pounds, totaling 8.41 pounds of hydrogen i'ri'the total gas, exactly the same as that contained in the steam and coal supplied.

blue water gas constituents of the weight balance equal the total gas in volume, weight, distributed elemental Weights and thermal value.

6. The total raw material is coal 100 pounds, steam 28.62 pounds, totaling 128.62 pounds. To waste and combustion is charged 41.84 lbs., leaving a net weight for reaction quantities of 86.78 lbs. The total weight of the gas is 86.78 lbs.

The weight balance certainly substantiates the statement, that all the elements, and the needed quantity of each, composing a carburetted water gas, produced from hard coal and oil, are fully contained and equationed in soft coal and steam'and no oil, including also satisfaction of all thermal requirements incident to the gas manufacture.

" 5. Needless to say, the illuminants and.

. To gas The gas Materials To waste To heat Hi 0 0 Wt. Cu. Ft. B. 'r. U

Hydrogen- 3.18 Wt 86. 78 1b 1,953 1,057, 736 Oxygen l 25. 44 Waste..- 8. 40 lb Material '10s. 02 lbs. 8. 40 l 33.44 8.41 45.32 33.05 Heat 33.44 lb w per cu. ft.

Gas 128 62 1,9530 f. 540 B.T. U.

, The cost of'thegas for labor and material, based upon .soft'coal' at $2.00 per short ton, double shift labor and a daily production of5000 M. cu. ft. of gas daily-1s:

0001 Cost Gas B. T. U. labor and on. It. Wt Cost cos I material 1953 100 lb $0.10 1,007.730 5000M. 128sh.ton 250.000 $30.00 Pcrcu.it.540 $220.00 1000- 51.210 512 .000 540,000 .0572 30000 lsh. 0011. 2.00 .234 1,000,000. 2.2a;

Description of dpgidmtua and its, functions.

of construction by which the process may be operable are within the scope of the specify cation and claims hereof.

In the accompanying drawings, like reference numerals indicate corresponding parts in the different figures of the drawings. Fig. 1, in vertical cross section and graphic, shows two similar generators of cylindrical design constituting an apparatus operable by the process described in this specification.

Fig. 2, is a top View of either of the similar generators shown in Fig. 1.

Fig. 3, and Fig. '4, are enlargements. of two certain parts of Fig. 1. I

Fig. 5, shows certain pattern derivations, and u Fig. 6 shows in vertical section a generator, applicable for intermittent operation of the process.

'most of the two shells.

In Fig. 1 (a) represents the outer of two hollow shells of a gas generator; (6) the inner shell; (0) indicates insulation material attached to the inner surface of the ollow shell (1)), Fig. 1; (d) is a fire grate; (e) is an air blast line with a valvelocated therein; (7") is an exit gas line with a Valve therein, indicated; (g) is a smoke stack with a cut-ofi valve indicated, to which is joined four tributary smoke pipes, indifferently designated (gt); it) shows the cross-section of a large washerike ring, which rests atop 1 the outer and inner-shells (a) and, (b), Fig.

'1, to the top rim of each of which .shells it is firmly attached; is a conic section, .the large circumference of which, evenly abuts all around the small circumference of (h),

Fig. 1,'to which it'is firmly attached on the down sides of both places; (j) represents, generally, a number of'rod braces, attached at one end to the undersurface of (i) Fig.

1, and the innersurface of hollow shell (b) Fig. 1'; 'Thus far in the assemblage, the outer concentric shells now support a plain.

circular ring-like sheet, firmly attached to their respective top r ms, wlnch circular sheet at its inner circumference unites with a collar-like conic sloping downward and toward the general center; the conic-being strengthened by rod braces from its lower surface to the inner surface of the inner- The inner surface of insulating forms a circular well strongly supported with a beveled opening at its top. Co'nics (l0) and (.2), Fig. 1, are firmly united by angle iron at their concentric circumferences and theunit formed by the union of the two material pieces rests upon, but is not attached to the beveled sides Fig. 1 of the opening into the interior well. Four circular openings .are provided in (70) Fig. 1, carriedwwith.

angle-irons to accommodate branch-fines,

circumference of which is securely attached place;

' upon and concentric with the conic (is) Fig.

opening at its center 1, and conic (70) Fig. 1 resting upon the bevel of the well opening (2') Fig. 1. A 10 series of grappling rings (p) Fig. 1 are attached to the top structure by which it may be put in place or lifted by the plant crane. The top plate, (m) Fig. 1, hasffour'ell1p tical holes, collared with angle-irons to accommodate the tributary stacks (gt), Fig. 1.

The top plate (m) Fig. '1- has a circular 1') Fig. 1, affording communication with t einterior of main stack (g) Fig. 1. A casting (8) Fig. 1 surrounds this central hole, (1') Fi land supports stack (g) Fig. 1, (t) an (w) Fig. 1 are coal ho pers, equipped -with sliding traps at the bottom and lids at the top. A pipe (:0) Fig. 1, enters the interior of the unit shown in Fig. 1, through its top as does also pipe (3 Fig. 1.

G remaning interior structure is the p1G fOI'me by union at their larger c1rcum'fe'rences, .of the two conics (we) and (bb)IFig. 1, the smaller of these being supported at its small circumference by angleiron to the undersurface of the top plate (m) Fig. 1.. The space bounded by the interior surfaces of the piece composed of conics (aa) and (67;) will be referred to as (A), Fig. 1; the irregular circular space bounded by the outside surface of this piece and the inner surfaces of (l), (k) and (m), Fig. 1 will be referred to as (B) Fig. 1; and the space bounded by the interior surface of the insulation (0) Fig. 1, and the outside surfaces of z and a Fig. 1 is designated c Fig. 1.

Situated to the right of the unit described,

isa second similar unit, corresponding parts of which are symboled the same as in the un%t)shown to the left with the addition of a Fig. 2 is a top view of either unit shown in Fig. 1, with corresponding lettering of parts, asanaid to the description of Fig. 1.

Fig. 3 is an enlargement of that part of the left hand unit of Fig. 1 indicated by the lettering. On this figure, because of its enlargement, are shown lugs (4) and (4), Figs. 1, 2 and 3, typical of a series attached firmly to respectively the top, (m) Figs. 1, 2 and 3, and to the rim (1)) Figs. 1 and 3, by which pins, (4), Figs. 1, 2 and 3, may firmly hold in place the assemblage of the top of theapparatus, in the manner shown, and yet, by their removal with the stroke of a hammer, permit the entiretop arrangement to be lifted by use of a crane and the loops (p) Fig. 2.

i Fig. t is an enlargement of. that part of the left hand unit of Fig. 1 indicated by the lettering. Without reference letters, a

sliding pipe section with collar, is shown in the tributary flue (gt) Figs. 1 and 4, which enables severance of the flue structure when the, lid of the apparatus is to be lifted.

. Fig. 5 is a sample cutting room pattern,

fully indicative, without comment, of the The apparatus is not shown as the best adaptation of the'process, nor is a perfect functioning of the process claimed for the mechanism. The twin set shown in the drawings is presented as one of any number 'of constructions, which may incorporate in its operation the tenets of the'subject'procoperation, is illustrated in the Fig. 1, with elaborations as shown ess, all mechanisms so functioning being within the claims hereof.

In operation, when coal is the fuel used, to coal the two units (Fig. 1) the coal is fed through hoppers (t) and (w), and (t') and (10), Fig. 1. The fuel passes downward through spaces B and B (Fig. 1), to the grates of the respective'units, (d) and'(d') Fig. 1. After the grates are filled, conforming with the declivity angle, the feedrises upon itself until theentire spaceS:,. i-ndicat as B and B (Fig. 1) are filled. When this occurs the traps in the bottoms of the respective hoppers are closed. Each hopper is filled for later replenishment of the interior fuel magazine, shown as the coal filled region of the right.hand unit Fig. 1, and its top is closed. Both units are then fired and air blasted, valves in pipes (e) and (g) and and (e) and (9) Fig. 1 being open, all other valves closed.

The 'first unit to attain reactively' high temperature in its first bed located upon its respective grate (d) or (d') Fig. 1, is put on a steam run to generate water gas, the other remaining on air blast.

To inaugurate the water gas run, stack and blast valves are closed, and the steam out contact.

central. stack (g), through the space A and through space G to and through the tributary stacks r (f). The hot combustion products pass, not through the fuel atop the lirebed in space H, but around it through space (land within it, through space A and with- The fuel in the fire-bed is burned. The fuel .above the fire-bed is heated. The rising temperature of the fuel, above the tire-bed, in-the magazine, space B. in the drawing, produces coke and distillation of the volatiles in the coal, and its partial or complete reduction to coke. The exit for such distillates is provided through pipe (wand 00, Fig. 1). As fuel in the tire-bed is consumed, it is automatically and continuously replaced with'fuel, wholly or partly' devolatilized to coke, from the magazine; and replenishment of the magazine occurs, from time to time by pulling the lever and sliding the trap in the bottom of a coal hopper, which is again refilled when the trap is closed.

The volatiles driven ofi from the magazine coal of the unit on air blast, have been carried over and delivered into the fuel magazine of the unit in gas-making-run. In the gas-making run the steam line (Y), Fig. 1 is delivering the steam requirement of the run into the magazine of the unit in run. Thus, the steam, so delivered, and the volatiles from the twin unit on air blast, aug- 'mented by distillates from the unit in gasmaking run journey downward through the magazine coal and increasing temperatures, through space B Fig. 1, upon the fire-bed atop grate (d) Fig. 1, through and among the incandescent carbon and, reacted, exit through the gas-line Fig. 1.

For a piece of fuel to reach the fire=bed it must ourney from the-ihopper traps,

down the entire vertical length of the'magazine. In the journey, it will experience repeated blasts and attain high temperature and devolatilization. The original fuel,

having lost much of its volatile fraction, in

its downward journey through the fuel magazine, reaches the fire-bed where, excepting for unconsumed quantities, its carbon. is either reacted through combustion, to dioxide and heat production or to monoxide and gas' production, dependent upon which cycle phase governs when'it is reacted. It matters little to whichreaction the carbon responds, as the heat balance is the same route from the uniton air blast to the one making gas.

The combustion prod Potential coke of the fuel, is constantly consumed; first, in combustion, to produce heat with which to distill coal volatiles and with which to produce the gas-making re-. actions, and, second, the reaction With steam, by which gas is produced consisting of OK- ides of the carbon and hydrogen released from the steam.

The process provides that part of the carbon of a fuel charge shall be combusted to furnish heat to drive off volatiles and elevate temperatures for the reaction of another part of the carbon with steam into its products. non-entrainment of combustion products and a gas composition into which the coal volatiles, fixed carbon and steam are reacted.

Combustion products that may evadethe exit draughts, through the main and tributary stacks, are carried over by the apparatus arrangement shown, into the unit on Also the process provides for gas-making run, where carbon dioxide is reacted With carbon into carbon monoxide -(CO +C 2CO). The sensible heat of the carbon dioxide is saved and the thermal cost for the conversion is confined to heat absorption. Also, the volume of the resulting carbon monoxide is double that of the introduced. carbon dioxide.

Any carbon deposited from vapor phase or other cracking, eventually arrives in the tire-bed, where its thermal value is reclaimed eitherthrough combustion and heat production or through reaction and gas pro duction. Heavy distillates from the fuel volatiles may so increase their hydrogen percentages and lower their boiling points, within the meaning of the process.

The scope of the process extends to and includes the use of any carbonaceous materials which will respond to the treatment prescribed by the process.

' Excepting for, let, the sensible heat carried outside the apparatus by air blast products, which is reduced by heat absorption of the magazine coal, and, 2nd, apparatus radiation, also reduced by the double shell 'in the ash, excepting for these items and with their deduction, it is inconceivable how any of the heat value of the coal can do aught but appear in the gas. There is no other exit. It is just this conversion of both the coal volatile and its fixed carbon, with exclusion from the gas of combustion products, which constitutes the essence of the process. In this, let it be mentioned, that thermal values areas indestructible as matter and that a heat balance is as true as a Weight-balance.

Concerning the twin set apparatus 1. Installation of appropriately located steam purge jets are advisable in any apparatus construction.

In the twin set of the drawings, such jets (not shown) may be placed toward the top of spaces C and C, Fig. 1..

After the gas-making run a quick steam delivery from this location. drives. the gas from the space indicated, to and through the fuel-bed; so that, with inauguration of the blast, it is steam, not gas, or its combustion products, which exit through the tributary flues. I

2. The varied composition and physical conditions as to size', regularity, etc., of the fuel, may necessitate, for good operation, mechanical changes of apparatuses. For instance, in the twin generator set shown in the drawing, the presence of slack, irregularities and mixtures of fuel sizes may make it advisable, for better operation, to deliver the distillates into the spaces A or C, Fig. 1 and into A or C Fig. 2, instead of into spaces B and B, Figs. 1 and 2. Such, or similar changes in operation would not constitute a departure from the process.

3. Steam for reaction purposes may be delivered into the generators, at any point, other than that indicated in the drawings, without departure from the process.

4. Though heat absorption by thev fuel contained in the fuel magazines, reduces the temperatures of the conic boundary walls of the zones, nevertheless, an edging of carborundu'm or other suitable material at the bottom edges of these conics, where they contact the firebed, will prolong the life of the interior structureof the generators.

5. In illustrating operation of the process with the twin units shown in the drawing, it was not necessary, for the purpose, to show doors in the shells, afiording access to the interior of the generators. Such door -may be installed at any suitable location.

Most standard shells are so equipped without specification. v

6. Though thercustomary thermal debit hasbeen made for drying the coal cited, the moisture fraction of the coal, in reality, will pass during blast from the magazine containing it, into the gas-making run of the twin generator and there be reacted with carbon into gas.

7. Operation difficulties of present carburetted water-gas practice, necessitating periodic shut-downs, due to carbon accumulations ,in the carburettor and super-heater are avoided by use of the process. Any such deposits eventuate in the fire-bed and are combusted or reacted without operation interruption.

8. Steam reacts with carbon, at nearly a thousand degrees below the temperature of some 2000 F. employed by best practice for the reaction. At sufficiently low temperatures, however, the. carbon monoxide percentage becomes as small as a few per cent and carbon dioxideincreases in .proportion. But, the'same weight of carbon reacted to carbon dioxide,.releases just double the quantity of hydrogen as it would, were the. reaction to carbon monoxide. And, at the temperatures of the process firebed, around and above 2000 F., carbon dioxide reacts'with carbon to carbon monox ide, in a quantity double that of the dioxide.

This is mentioned in connection with the in- 1 movable with the conics attached to its under surface.

10. The twin-set functions .as a continu-' ous operation with antomaticfrml feed.

11. It is not claimed in operation of the process that any apparatus will drive ofi" all possible volatiles of the coal nor completely exclude from the gas all products of combustion. The process includes the normal departures from perfect operation incident to any operation.

12. Heat absorbed for evaporation of the moisture in the coal is reclaimed, as the wator vapor is carried over to the unit in gasmaking run,where it is reacted with carbon, along with the supplied steam quantities.

13. It is to be noted that in delivering reaction steam into the magazine, on its journey downward, its reaction with carbon is possible, with the increasing temperatures, before it reaches the fire-bed proper. Fuel whose carbon is so reached has not completed its total heat treatment for devolatilization.

Adopting the quantities earlier shown in the weight, balance as the operating efficiency of the twin set, there results:

The thermal value of the coal, shown in analysis, is 14,450 B. T. U. per pound, or

1,445,000 B. T. U. in the 100 pound sample, the asification of which, produced 1953 on. t. of 540 B. T. U. gas, or 1,057,736 B. T. U. in total. Thus the mechanism shown, becomes a heat machine of 73% efiieiency Forstall, in Kent, rates the carburetted water gasoperation at 61%.

Estimating hard coal or coke at $8.50 per ton, oil at 6 per gallon of 7 lbs. and soft coal at $2.00 per ton, an economic eiiiciency dication of the variety. of methods and apparatuses by which the process may be applied. No reference symbols are employed, as the operation is quite apparent.

The cycle of the single unit is air blow and steam run. The course of theblast is indicated through the fuel and the combustionkproducts are shown to exit through the stac I Distillates, produced duringthe air blast,

may be-conveyed through the pipe, leading from the top of the generator to a relief holder, not shown, and returned, through the same pipe, to the generator duringthe gas-making run, or they may be passed through 'a condenser or dephlegmator, as shown. In the latter case the fixed gases may be permanently withdrawn from the apparatus for purification and useand such condensates as desired, alone, returned to the apparatus. Taps are indicated, as amethod for -Withdrawal' of any desired fractions. The unit may be united for continuous operation with another generator of likeor dissimilar ;construction, it being within the scope of the process to utilize any method of operation :or mechanical arrangement, which permits the process to function.

It'is within the scope of the process to provide for introducing reaction steam for the gas making run through the same inlet as that which admits air quantities during the blast and toprovide a common exit for reaction gas quantities and combustion products, conducting them through their separate and respective channels outside the generator.

The originality of this invention'lies in -newcombinations; of things known, which encompasses process novelty.

vA new product. ,inaybe discovered or a newmethod for obtaining an old product, but the process for doing these things must be expressed-in known quantities to function. In a sense, the process gas is producer gas, excepting that combustion products are diverted from the gas-make;- it is coal gas excepting that potential coke is reacted to combustible gas; it is water gas, excepting that. devolatilization supplants carburetting.

By the .process, depleted,- nitrogenous, thermally weak producer gas is replaced by a hot'gas of carburetted water-gas constituency; coke, tar and gas characterizing coal Igasproducts, become hydrogen, monoxide and illuminants, and the use of hard coal or coke and 011 in producing water gas 18 supplanted by the use of soft coal and steam Without oil, and the functions of-carburettor and superheater of water gas practice, are performed within the magazine and reactively hot carbon of the process reaction zone.

In general concerning the process;

One pound of carbon, plus heat, combines with one and one-half pounds of water to make two and one-third pounds of carbon monoxide and one-sixth pound of hydrogen. If hydrogen be given a thermal value of 61,523 B. T. U. per pound, and carbon monoxide, a value of.4,368 B. T. U. per pound,

the products above yield in combustion- 21,44c T. U.

If carbon has a thermal value of 14,544 B. i

B. T. U. thermal gain between reaction prodnets and. quantities reacted, is just exactly how much cooler the fire bed is because of the reaction. 7,000 B. T. U."s of sensible heat have become 7 ,000 B. T. U.s of latent heat, reconvert'ible again by combustion of the product gases.

High temperatured reactive contact strives for equilibrium through heat absorption and the conversion of sensible heats into latent heats. (JO plus sufiicient heat and carbon 1 15 is 200; acetylene water enough heat, is methane plus carbon monoxide,

Oxygen abandons its hydrogen for carbon union, thermal value and the conversion 0 sensible heat intensities to latencyby heat absorption. The remaining carbon saturates to methane in'equilibrial' accommodation.

The most important agencies functioning in these heat conversions are the great combustion products, water and carbon dioxide.

The processpresented is that of establishing, by combustion, intense sensible heat within a carbonaceous material, which heat is made available for use outside and away from the material, by its absorption and conversion to latency through the production of gaseous reaction products, the thermal value of which is augmented by entrainment of volatile heat values and exc usion of thermally valueless combustion products and in this combination is the process claim for novelty.

Any carbonaceous materials which severally, or in combination, or in combination with other materials may be used in' operation of'the process are included within its scope, including such physical states as solids, semi-solids, liquids and combinations of these.

It will be seen that the present process serves, in effect, to maintain a combustion zone and a coking zone both supplied with carbonaceous fuel, the coking zone being above and in gravity communication with the combustion zone. In operating thetwin 7 process, there are, of course, two combustion zones and two coking zones. The process may be so operated as to produce any desired degree of coking of the solid fuel.

What is claimed as new is:

1. A process for manufacturing a heating and illuminating gas, which consists in combusting part of a quantity of solid fuel by air blasting and diverting products of such,

combustion outside and away from the combustion zone, and during such combustion period distilling volatiles out of and away from solid fuel superimposed upon the burn ing fuel, and when a desired incandescent heat is attained'therein discontinuingsuch combustion, and then delivering into incandescent fuel steam and volatiles distilled from solid fuel, thereby producing, enrich-- ing and fixing a combustible gas.

2. A process for manufacturing a combustible gas, which consists in establishing a plurality of incandescent beds of solid fuel, in at least one of which beds combustion with air is in progress, and in another fuel bed carbon and steam are bein reacted to water gas, and distilling volati es from the solid fuel superimposed upon the bed which is in combustion, and conducting such distillates away from the fuel from which they are distilled, and delivering them, mixed.

with steam, into another of the incandescent beds of solid fuel in which water gas is being produced by the reaction of steam and fuel, of air and fuel are excluded, and thereby forming a combustible gas.

3. A continuous process for manufacturing a heating and illuminating gas, preferably from any high volatile fuel, which consists in establishing two incandescent solid fuel beds, each having a distillation bed of solid fuel resting thereon, delivering air intothe'first such bed, and producing combustion and from which combustion products fuel bed, delivering air to the-second such fuel bed, distilling volatiles in like manner as before from the distillation bed of solid fuel atop the second bed of incandescent solid fuel, delivering volatiles so derived and steam into the first incandescent solid fuel bed, whereby alternately one or the other of the two solid fuel beds is in combustion with air supplied, and the other with air excluded, is producing the gas composed of the constituents of water gas from the reaction of steam and carbon and illuminants derived from volatiles distilled from the solid fuel without material dilution with any substantial amount of combustion products resulting from the combustion of the fuel.

4. A process for producing combustible gas which consists, in incandescing one solid carbonaceous bed, withdrawing products of combustion therefrom while simultaneously utilizing their heat to distill volatiles from a second carbonaceous bed, delivering distilled volatiles, with their entrained heat, and with steam to a third solid carbonaceous bed of partially devolatilized solid fuel in incandescent state, the latter bed serving, with steam and volatiles supplied thereto, to make, enrich and fix water gas.

5. A process for producing a combustible gas, which consists in establishing two separate incandescent beds of solid fuel into one of which air is introduced and combustion is in progress, and in the other air is excluded reacted into water gas, whereby water gas is produced and enriched, and combustlon products are substantially excluded there- I from.

6.'A process of producing combustible gas, which consists in maintaining two combustion and two coking zones all supplied with solid carbonaceous fuel, each coking' zone being above and in gravity-communication with one of the combustion zones, each of which combustion zones is in a state of incandescence, and, establishing combustion the first combustion zone with air, drawing resultant combustion fprocluctherefrom, utilizing heat of said first combustion zone and of said combustion productsto distill volatiles from solid fuel in the first coking zone, conducting volatiles so derived with entrained heat and steam into and through the body of fuel in the second coking zone, said steam and volatiles, together with any additional volatilesderived in the second coking zone being conducted into contact with-incandescent solid fuel in the second combustion. zone to produce, en-' A solid fuel, and While reacting the fuel mass with steam into water gas delivering thereinto volatiles 'distilled from solid carbonaceous fuel, whereby an enriched water gas ,is produced without substantial entrainment of combustion products produced from the combustion of the fuel and air.

8. A process of making combustible gas intwin gas generators, each generator havin a gas generatin solid fuel bed and Ya so id bituminous uel distillation zone, which consists in air blasting a gas generating fuel bed to incandescen'ce, distilling the generating combustible gas by -mixed steam and distillation products through said-gas generating zone of the-secbituminous fuel in a distillation zone, by passing the air blast gases therearound, passing products of said distillation from one distillation zone to the distillation zone in the second unit-and mixing steam with said products prior to entering the gas generating zone of the second unit, and then passing the 0nd unit. I

9. A process of making combustible gas in'a generator having a solid fuel bed and --a solid bituminous fuel distillation zone which consists, in air-blasting the gas generating solid fuel bed to incandescence, distilling solid bituminous fuel in the distillation zone by heat from the air blast gases,

passing products of said distillation outside into and through a distillation zone, and

mixing steam with said products prior to entering the gas generating zone and after entering the distillation zone, and then enerating combustible gas bypassing the mixed steam and distillation products through said gas generating zone; I

'10. A process for'producing a combustible gas, which consists -1I1 producing water gas from any solid fuel by intermittent air blast and steam contact, and during the air blast period diverting away the products of combustion with air,--'and distilling volatiles from solid fuel which is in contact with the incandescent fuel'bed, and during the period of steam contact delivering with the steam, distillates from solid fuel for reaction with the steam in the incandescent fuel bed whereby an enriched water gas is produced substantially free from combustion vproducts from the reaction of air and fuel.

11. A process for producing a' combustible gas from solid carbonaceous materials of the higher volatile classification, which consists in reacting carbon of such materials and steam into water gas by alternate-air blast and steam contact, and distilling, and removing from combustion by the air blast, volatiles from such materials during the air blast periodQwith heat produced thereby,

and contacting volatiles derived in such man-y ner and steam with carbon of such materials rendered incandescent by air blast, whereby a combustible gas of enriched water gas constituency is produced, substantially free ing.

12. A process for producing a combustible gas, which consists in incandescing byair blast, one of two solid fuel beds and with heat so produced distilling volatiles from from the combustion products of air blastthe solid fuel of the second bed and conduct- I said first fuel bed whereby a combustible gas is produced.

HAROLD R. BERRY. 

